Abstract

AbstractTapping is a challenging process at the end of the value chain. Hence, tool failure is associated with rejected components or expensive rework. For modelling the tapping process we choose a mechanistic approach. In the present work, we focus on the tool model, which describes the deflection and inclination of the tool as a result of the radial forces during tapping. Since radial forces always occur during tapping due to the uneven load distribution on the individual teeth, the tool model represents an essential part of the entire closed-loop model. Especially in the entry phase of the tap, when the guidance within the already cut thread is not yet given, radial forces can lead to deflection of the tool. Therefore, the effects of geometric uncertainty in the thread geometry are experimentally investigated, using optical surface measurement to evaluate the position of the thread relative to the pre-drilled bore. Based on the findings, the tool deflection during tapping is mapped using a cylindrical cantilever beam model, which is calibrated using experimental data. The model is then validated and the implementation within an existing model framework is described.

Highlights

  • IntroductionIn industrial applications and in everyday live, threaded joints are widely used as detachable connecting elements

  • Tapping is a challenging process at the end of the value chain

  • We focus on the tool model, which describes the deflection and inclination of the tool as a result of the radial forces during tapping

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Summary

Introduction

In industrial applications and in everyday live, threaded joints are widely used as detachable connecting elements. Uncertainty arising from the interlinking of both process steps are positioning errors, like axis offset and inclined pre-drill bores [4]. Kim et al [9] describe the tool deflection during ball-end milling They calculate the cutter deflection due to the cutting force using a two-step cylindrical cantilever beam and estimate the form error of the finished part. The influences of process faults on tapping are described by Dogra et al [2, 15] They use a mechanistic model approach to predict the effect of axis offset, tool runout and synchronization errors on the resulting torque and forces. Mezentsev et al [16, 17] describe the effect of axis offset and tool runout on tapping, with focus on the resulting radial forces and the thread geometry. The integration of the tool deflection model into an existing framework to simulatively investigate the effect of uncertainty on the tool deflection during tapping is described

Effect of Tapping Tool Deflection on Thread Geometry
Model Description
Model Calibration
Experimental Model Validation
Model Framework
Summary and Outlook
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