VA R D E X I n d u s t r i a l S o l u t i o n s
METRIC
VARDEX
Vardex Advanced Threading Solutions
VARGUS Ltd. is a world leading developer, manufacturer and supplier of high-quality, precision cutting
tools. The companys VARDEX product line is the number one source for threading solutions worldwide
and includes the largest range of thread turning and thread milling solutions implemented in almost
every metal industrial segment.
Thread Milling
TMSD
TM Solid
Standard TM
Thread Turning
microscope
Standard TT
For over 50 years, VARDEX has been the #1 name of indexable threading in the metal industry. Since introducing the first
triangular laydown thread turning and thread milling insert systems, the VARDEX product line offers thousands of solutions, for
virtually every thread standard and application, most available for immediate supply. From the original VARDEX tool design to
its threading tool systems of the 21st century, VARDEX threading continues to live up to its name as the industry standard of
threading. VARDEX - Making Threading EASY!
VARDEX Thread Turning
A complete range of standard indexable thread turning cutting tools from fine to large and extra-large pitches, as well as an
extensive range of insert types such as laydown, vertical, multitooth and more. The VARDEX thread turning line offers solutions for
applications from minute to large bores.
VARDEX Thread Milling
VARDEX provides the most extensive and professional thread milling cutting tool solutions available in the market. Our offering
includes a wide range of single and multi-tooth indexable inserts as well as solid carbide tools. The VARDEX thread milling line
also offers a large variety of pitches for applications in shallow and deep holes suitable for miniature to large diameters.
INDEX
OIL & GAS
VALVES
FITTINGS
GEAR
Page 4
Page 6
Page 7
Page 8
DIES & MOLDS
AEROSPACE
AUTOMOTIVE
MACHINE BUILDERS
Page 10
Page 11
Page 12
Page 13
WIND POWER
POWER GENERATION
MEDICAL
DENTAL
Page 14
Page 15
Page 16
Page 17
VARDEX SPECIAL
TOOLS
VARDEX
WORLDWIDE
Page 18
Page 19
OIL & GAS
Vardex has designed and developed
a unique threading line for the Oil
& Gas industry. The innovative and
creative response VARDEX offers
to it's customers has established
VARDEX as a front line player in this
growing market.
Thread Method
Applications
Casing, Tubing and Couplings
Thread Turning
Thread Milling
Line Pipe
Rotary Drilling Connections
Gate Valves, Wellhead
Subsea Gate Valves - "Christmas Tree"
Threading Standard
API-5CT: Buttress Casing, API Round, EL-Extreme
Line, VAM, OTTM, OTTG
API-5L: LP, NPT
API-7: NC, Regular, FH, IF, Hughes H-90
NPT, BSP, UN, ACME, ST. ACME, Modified ACME
NPT, BSP, UN, ACME, ST. ACME, Modified ACME
The VARDEX Oil & Gas line offers both a comprehensive variety of standard tools as well as an extensive
range of tailor-made tools manufactured to customer specifcations and distinct applications.
TMSD U
Helicool
Standard
OIL & GAS
Case Study 1
14D - New API Insert
Background
The customer was using a competitors tool to mass produce couplings. As this method offered only 35 pieces per
cutting edge, the customer looked for an alternative to improve output.
The VARGUS Solution
A tailor-made VDI holder with VARDEX 14D style inserts was produced for the customer's unique clamping
system. The result - an incredible 400% increase in tool life!
Test Details
Application
Component
Material
Holder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Time
4.5" X 5 BUT x 55
Coupling
N80
T03 HOLDER L1=121 168/256
14DIR5BUT752T+ (14D)
160
446
5
15 sec.
150 pieces per cutting edge - Improved tool life by 400%!
Case Study 2
Multi+ for Mass Production
Background
A coupling manufacturer had to produce a large quantity of products in a short delivery time. He applied
a single tooth standard insert and completed the threading in 12 passes. The cycle took 41 seconds.
The VARGUS Solution
Using Multi+ indexable thread turning inserts, the threading cycle was complete in just 6 passes and
21 seconds. The Multi+ inserts reduced threading cycle time by 49% and increased tool life by 100%.
The customer is now able to meet delivery deadlines.
Test Details
Application
Component
Material
Holder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Times
2 7/8" x 8 APIRD x 60
Coupling
NL 80
AVRC 40-4
4IR8APIRD2M+
160
660
6
21 Sec.
49% time savings and 100% increased tool life!
VALVES
To best serve the non-symmetrical shape
of Valves, VARDEX offers its renowned
thread milling system, thus eliminating the
common problem of broken taps and the
necessity to build special and complicated
fixtures as required for thread turning.
Case Study
MiTM Replaces Taps for the Valve Industry
Background
While using a tap, the customer experienced repeated problems with
tap breakage and unsatisfactory surface finish, which required additional
manual finishing operations.
The VARGUS Solution
By using the MiTM Multi flute indexable thread milling inserts, the
customer machined the job continuously without tool breakage and
with excellent surface finish.
Test Details
Application
Component
Material
Holder
Insert
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
1 x 8UN x 35.0
Gate Valve
Cast Steel
RTMC 2520-44S3 (MiTM)
R25I8UNTM VBX
70
1100
0.05
2min 40 sec.
Uninterrupted production; superb surface finish!
Helicool
TM Standard
TMSD Shell Mill
Shell Mill
FITTINGS
The worldwide Fittings industry encompasses
a range of applications, from the production of
simple cast iron fittings to the machining of highly
sophisticated, high quality products. VARDEX has
a wealth of experience in threading requirements
for Fittings and provides an extensive scope of
solutions for both turning and milling.
Case Study
Helicool for Fitting Production
Background
Previously machined by thread turning tools, the component thread was often scratched by the resulting chips.
Due to the demand for a high quality surface finish, an additional operation was required and this increased
machining time.
The VARGUS Solution
In order to overcome the problem caused by the chip flow, VARDEX offered the Helicool solid thread milling alternative and,
while the surface finish met the highly demanded requirements (because the chips are promptly removed by the coolant),
this new method took only 17 seconds compared to the previous operation that took twice that amount of time.
Test Details
Application
Component
Material
Tool
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
No. of Passes
Cutting Time
2"x14NPTx13.55
Fitting
Stainless Steel 316
HC16142L19-EI14NPT TM VTH (Helicool)
100
2234
0.034
1
17 Sec.
Reduce machining time by 50% and get excellent surface finish!
Helicool
Mini-L
GEAR
Advanced Technologies for Gear,
Spline & Rack Manufacturing
VARDEX presents an original and innovative
solution for the gear milling industry,
offering a competitive alternative to the
traditional Hob system. Gear manufacturers
can now mill external splines, external
cylindrical gears, sprockets and racks as well
as many additional gear applications with
VARDEX gear milling tools.
VARDEX GEAR MILLING Concept
Milling tools with multi-flute indexable carbide inserts.
Tailor-made inserts and holders designed per customer application. The inserts have the exact required profile shape
(evolvent, involute or any other profile) which is transferred onto the component.
Vardex System Advantages:
Super Fast - At least 50% less machining cycle compared to any other method:
- Carbide inserts - High cutting speed
- Full profile per pass - One pass per slot
Long Tool Life - Tough sub-micron substrate insert coating
Machining - Simple set- up and use on standard 3.5 axis CNC milling machine
Economical - Absolute Price/Performance advantage over existing technology
High Precision - Gears up to Class 7 according to DIN 3962 or Class 11 according
to ANSI 390.03
- Involute Splines according to DIN 5480 or ANSI B92.1
- Straight sided Splines according to ISO 14-1982
Accuracy - No need for additional machining
Cutting Edges - Up to 3 cutting edges per insert for extended tool life
Quality - High surface finish
GEAR
SPLINE
Shell Mill
End Mill
RACK
Disc Mill
U Style
UT Style
Case Study 1
GEAR
Gear Production
Background
One of Europes leading gear manufacturers traditionally produced splines using a HSS hob. The production cycle for each
gear took 60 seconds. The customer wanted to reduce this cycle time.
The VARGUS Solution
After analyzing the project, the indexable carbide Gear Milling tool was applied and, after utilising the tool for a
regular mass production run, machining time was reduced by 75%.
Test Details
Application
Component
Material
Toolholder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Time
Module 0.75
Gear (Diameter 40.5, 52 teeth)
42CrMoS4V
GMD10S D80-22-2U
(10 Cutting edges)
2UEM0.75GM VBX (Gear Milling)
125
500
1
4.3 min.
Reduced machining time by 75%!
Case Study 2
Rack Production
Background
With an existing HSS cutter, one rack manufacturer produced 4 teeth in one pass in a total machining
time of 10.74 minutes.
The VARGUS Solution
To reduce this long cycle time, VARDEX offered the Gear Milling solution with indexable carbide inserts.
Allthough producing 2 teeth at a time, the total machining time, when using the new tool, is only 3.3 minutes!
Test Details
Application
Component
Material
Toolholder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Time
Module 5.0
Gear Rack
ST52-3
GMD16S D160-50-5U
(8 cutting edges)
5UEM5.0GM VBX (Gear Milling)
150
300
1
3.3 min.
Reduced gear rack production time from
10.74 min to 3.3 min!
DIES & MOLDS
Dies and molds which are characterised
by their non-symmetrical shapes and hard
materials are ideal components for thread
milling. Thread milling also avoids the
expensive risk of broken taps in the workpiece,
which are difficult to remove. VARDEX offers a
wide range of thread milling solutions for the
die and mold industries, including solid carbide
as well as indexable insert cutting tools.
Case Study
TMSD Replacing Taps in the Mold Industry
Background
A mold production factory manufactures various types of threads for lifting rings such as M30x3.5/M36x4/M42x4.5/
M45x4.5/M48x5/M56x5.5/M64x6. The customer generally used a variety of taps for this range of applications, but the
taps tended to break. They are relatively costly in such large sizes and, in addition, the cost of mold making is very high
and any damage caused by broken taps not only delays production and delivery, but is also expensive to repair.
The VARGUS Solution
As a solution, VARDEX offered the TMSD thread milling tool for deep holes, which it accomplishes with ease due to
the low load applied to the inserts. In addition, because the TMSD inserts have partial profiles, the customer can
also apply the same tool to the production of a variety of threads.
Test Details
Application
Component
Material
Holder
Insert
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
M48x5x98
Mold
Cast Steel (28-32 HRc)
TM4CS40W42 120-3U (TMSD)
3UIDH60TM VBX
110
834
0.25
3.85 min.
TMSD performs various applications with just one tool!
Helicool
10
MilliPro
TMSD
MilliPro HD
AEROSPACE
The Aerospace industry is known for the high
level of accuracy required in its manufacturing
processes. VARDEX precision tools meet the high
level demanded by this market and are suitable
for machining Aluminum, Titanium, Magnesium
and high temperature alloys customarily used in
this industry. The unique aerospace MJ and UNJ
standards are available as popular stock items.
Dedicated Standards for the
Aerospace Industry
Standard
Pitches
MJ
UNJ
0.7 - 3mm
48 - 4 tpi
Case Study
Helicool for the Aerospace Industry
Background
The component forms part of an hydraulic actuator for an aerospace
instrumentation product and, as such, the demand for a very accurate
thread finish is paramount.
The VARGUS Solution
The VARDEX tool out-performed all others by 20% and with a far
superior thread finish.
Test Details
Application
Component
Material
Tool
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
x 14NPTx13.5
Hydraulic Actuator
Stainless Steel PH1734R-009
HC16142L19-EI14NPT TM VTH (Helicool)
110
2500
0.04
10 sec.
Outstanding surface finish!
TT Internal
TT External
Helicool
MilliPro
TM Standard
11
AUTOMOTIVE
The fast-moving, mass production manufacturing
lines in the Automotive industry require quick
delivery and on-the-spot responses and speedy
supply of products. In order to reduce production
costs, VARDEX offers flexibility and creative
special-purpose tooling solutions demanded by
this industry.
Case Study
V6 - for Greater Cost Savings
Background
In order to find the most economical tool for the job, one customer tested 3 different suppliers of threading inserts.
Supplier 1 - Total threads per insert: 1,050
Supplier 2 - Total threads per insert: 1,162
The VARGUS Solution
VARDEX - Total threads per V6 insert: 3,040
VARDEX V6 - the innovative laydown thread turning insert with 6 cutting corners proved that it is the ideal
tool for the job, offering the longest tool life: tool life is increased by over 30 percent.
Test Details
Application
Component
Material
Toolholder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Time
M26x1.0x28.0
Shock Absorber
SAE 4340
AVR 20-3
3IR1.0ISO-6C VKX (V6)
90
1100
4
12 sec.
V6 insert: The most economical tool for the job with
6 cutting corners!
HTC
12
Helicool
TMSD
MACHINE BUILDERS
The wide range of applications in the Machine
Building industry requires a multitude of threading
tool profiles. VARDEX is proud to offer a variety
of over 30,000 tools to provide comprehensive
threading solutions.
Case Study
Saving Costs by Using Standard VARDEX Tools
Background
A thread of 118 x 12 UN x 48 mm was required for a heat exchanger application. In the past, the
customer used a competitors special tool to produce the thread. As this was tailor-made, the cost
was relatively high and the tool had a long delivery time.
The VARGUS Solution
VARDEX offered a standard TM Solid tool with helical flutes and, as a result, the customer considerably
reduced both the delivery time and overall tooling costs.
Test Details
Application
Component
Material
Tool
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
118"x12UNx48
Heat exchanger for a water
desalination facility
Alloy Steel
H20199L51-I12UNF TM VTH (Helical)
94
1500
0.07
19 sec.
Reduced tooling costs with VARDEX standard TM Solid!
TT Standard
MilliPro
Helicool
TMSD Shell Mill
13
WIND POWER
The growing popularity of green energy supply has
created increased demand for wind turbines. To satisfy
this trend, VARDEX offers a comprehensive line of
thread milling tools the VARDEX TMSD line is the
optimal solution specially designed for deep hole
applications.
Case Study
TMSD for the Wind Turbine Industry
Background
Using a tap to manufacture a wind turbine component, a stator ring support, required stopping the
manufacturing process to add oil as coolant to aid cutting during machining. This procedure created a situation
where the manufacturer was dependant on the experience and skill of the machine operator, who was required
to continuously monitor the machine.
The VARGUS Solution
VARDEX offered the TMSD thread milling line for the production of deep holes. The results: the machine did not
require constant oiling of the thread area and the process was continuous and completely secure. An added
benefit is that TMSD utilises indexable inserts, so tooling costs have been considerably reduced.
Test Details
Application
Component
Material
Toolholder
Insert
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
M24x3x52
Wind Turbine - Stator Ring Support
ST37
CTM2SC16C21-80-2U
2UIDC60TM VTX (TMSD)
162
2500
0.23
1.25 min.
Increased security and stability as well as reduced costs!
TMSD Shell Mill
14
TMSD (Mini L Style)
TMSD (Style U)
POWER GENERATION
ION
The power station is a multi-faceted system of
production, development and maintenance that
requires an unlimited range of both standard and
special threading applications. With its extensive
scope of threading tools, VARDEX provides
complete and comprehensive threading solutions
for the Power Generation industry.
Case Study
TMSD for the Power Generation Industry
Background
While threading a large and costly turbine, the manufacturer needed to reduce the long production cycle and decrease
overall tooling costs. As the turbine is both sizable and valuable, any malfunction would cause damage and high loss to
the customer. Therefore, the need for a safe and reliable process is essential.
The VARGUS Solution
VARDEX offered the thread milling TMSD Shell Mill System with 18 indexable inserts. The production cycle was reduced
by 45% in one pass only (the previous method required 3 passes per thread) and tool life was increased by 62%.
Test Details
Application
Component
Material
Toolholder
Insert
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
No. of Passes
Cutting Time
580x9 ARTILERIEx240
Turbine Component for the Power Sector
Alloy Steel Forged
TM18S-250-605V(18 Flutes)
5VIRD9ARTILVBX (TMSD)
119
152
0.12
1 Radially / 27 cycles
2.5 HRS
TMSD: Increased tool life by 62% and reduced production
time by 45%!
TMSD Shell Mill
TMSD (Style U)
Shell Mill
TT External
(V Style)
U Style for
Coarse Pitch
15
MEDICAL
The surgical bone plate market is a rapidly developing area of
the Medical industry.
The necessary components are largely manufactured from
titanium and stainless steel, and they require non-standard
profiles. VARDEX has developed a dedicated TM Solid Carbide
tool for the bone plate industry. These high-quality tools
provide an excellent solution for the multi-start conical
threads required in these demanding applications. Along
with the standard small application threading tools, VARDEX
offers a complete solution for miniature threads.
Case Study
TM Solid for Medical: Metric 20 Taper
Background
A surgical bone plate manufacturer had to produce a special Metric 20 taper thread with 2 starts and was achieving just
50 threads per tool. Another solution was thread milling with a single tooth, but the machining time of 30 seconds was
too long and thread quality was unacceptable.
The VARGUS Solution
We offered the customer the TM Solid Carbide thread milling tool. After producing the 20 taper, tool results were
excellent. The customer manufactured 2,800 threads with one tool and the surface finish was outstanding. Both starts
were made in one pass and the total machining time for each thread was only 3 seconds!
Test Details
Application
Component
Material
Tool
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
No. of Passes
Cutting Time
6 x 0.5 x 5 (2 starts)
Surgery Bone Plate
Titanium
S060L0.90 I 0.5TAP60 TM VTH
(Taper)
80
5660
0.03
1
3 Sec.
Excellent surface finish quality in only 3 seconds!
MilliPro
16
Taper
DENTAL
Dental implant technology is relatively new in dental
treatments but, due to its increasing popularity, implants
are being mass produced with a special demand for
superior surface finish and thread quality. VARDEX has
developed the MilliPro Dental as a unique solid carbide
thread mill for such applications.
Commonly Used Standards
M Coarse
M1.0x0.25
M Fine
UNF
M1.4x0.25
M1.2x0.25
M1.4x0.30
0-80
1-72
M1.6tx0.35
M1.8x0.35
M2.0x0.40
M2.0x0.35
M2.5x0.45
Case Study
MilliPro for the Dental Implant Industry
Background
Dental implants are mainly produced from titanium and stainless steel, and both
botth are
ar ha
hard
ard to
o
machine with taps, especially when such small diameters are required. In addition, taps create a
small burr at the bottom of the thread that is almost impossible to remove.
The VARGUS Solution
The MilliPro Dental tool provides a perfect solution for this application
and has increased tool life by 25% with excellent surface finish.
Test Details
Application
Component
Material
Tool
Cutting Speed V (m/min)
RPM
Feed f (mm/flute)
Cutting Time
1-72UNx6.0
Dental Implant
Titanium
D3T03014L057-I72TM VTH
(MilliPro Dental)
90
20,000
0.02
6 Sec.
Increased tool life by 25%!
MilliPro Dental
MilliPro
17
VARDEX SPECIAL TOOLS
VARDEX engineers and toolmakers have the know-how and
experience to design special cutting tools tailored
lored specifically
to customer requirements. Whether its a special,
cial, complex
shape or a non-standard size, our Special Tools
ols service
can quickly produce the tool you need using the latest
techniques and technology.
VARDEX expertise
Quick quotation
Prompt delivery time
Case Study
Special Tool for Extremely Large Pitch of 20mm
Background
The customer had to produce a TR180x18x310. He could not find a standard tool for such a unique
application and therefore asked us for a solution.
The VARGUS Solution
We offered a special insert based on a 16mm carbide rod. A trapez
profile was then ground on both sides of the rod, creating 2 cutting
edges. This tool completed the thread in only 5.5 minutes and the
surface finish was excellent.
Test Details
Application
Component
Material
Holder
Insert
Cutting Speed V (m/min)
RPM
Number of Passes
Cutting Time
TR180x18x310
Lifting device for heavy machines
S355J2G32
NL40-16U Special
2M16THE18TR Special (Mega Line)
85
160
50
5.5 min.
The ideal solution for extra large pitches!
18
VARDEX WORLDWIDE
Brazil
Vargus Brazil
+55 (47) 3084-8001
[email protected]
China
Vargus China
+86 21 516 88300
[email protected]
Vargus Scandinavia
+45 8794 4100
[email protected]
France
Vargus France
+33 1 4601 7060
[email protected]
Germany
Vargus Germany
+49 7043 36 161
[email protected]
Ibrica
Vargus Ibrica
+34 977 52 49 00
[email protected]
India
Vargus India
+91 2135 654748
[email protected]
Israel
Vargus Israel
+972 3 537 3275
[email protected]
Poland
Vargus Poland
+48 46 834 9904, 603 888 064
[email protected]
Switzerland
Vargus Switzerland
+41 41784 2121
[email protected]
United Kingdom
Vargus Tooling UK Ltd.
+44 1952 583 222
[email protected]
USA
Vargus USA
Denmark
Iceland
Finland
Norway
Sweden
For the complete list of VARDEX worldwide distributors, visit our website at www.vargus.com
VARGUS Ltd.
[email protected]
www.vargus.com
19
VARGUS Tool Selector and
Ius CNC Program Generator
The most popular and advanced thread turning and
thread milling software on the market today.
Now available in 3 versions
at www.vargus.com:
VARGUS
VARGUS
VARGUS
ONLINE
D E S K TOP
setup.exe
VARDEX Industrial Solutions
Visit VARGUS
VARGUS Ltd.
[email protected]
www.vargus.com
221-01151
METRIC EE
03/2015
EDITION 01/911
