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TECHNICAL PAPERS

Mechanistic Model for Tapping Process With Emphasis on Process Faults and Hole Geometry

[+] Author and Article Information
Ajit Pal S. Dogra, Shiv G. Kapoor, Richard E. DeVor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801

J. Manuf. Sci. Eng 124(1), 18-25 (May 01, 2001) (8 pages) doi:10.1115/1.1430237 History: Received December 01, 1998; Revised May 01, 2001
Copyright © 2002 by ASME
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References

Johnson,  E., 1950, “Some Experiments on Tapping,” Proc. Inst. Mech. Eng., 162, p. 412
Stromberg,  N. O., 1942, “Tap Design,” Tool Engineer, pp. 99–104.
Lehde, J. W., “Practical Aspects of Tapping,” American Society of Tool and Manufacturing Engineers, Paper No. 697, pp. 1–16.
Henderer,  W. E., 1977, “On the Mechanics of Tapping by Cutting,” ASME J. Ind., 99, pp. 257–262.
Felder,  E., Gilormini,  P., Tronchet,  L., and Leroy,  F., 1982, “A Comparative Analysis of Three Machining Processes: Broaching, Tapping and Slotting,” Etude DGRST Materiaux, 80, pp. 512–513.
Carroll,  L., 1995, “Tapping Deep Hole,” Cutting Tool Engineer, 47, No. 5, pp. 36–43.
Agapiou,  J. S., 1994, “Evaluation of the Effect of High Speed Machining on Tapping,” ASME J. Ind., 116, pp. 457–462.
Sabberwal,  A. J. P., 1961, “Chip Section and Cutting Force During the Milling Operation,” CIRP Ann., pp. 197–203.
Stabler,  G. V., 1964, “The Chip Flow Law and its Consequences,” Proceedings of the International MTDR Conference, University of Birmingham, Sept. 1964, Advances in Machine Tool Design and Research, p. 243.
Amerago,  E. J., 1967, “Cutting With Double Edge Tools: Symmetrical Triangular Cuts,” Int. J. Mach. Tool Des. Res., 7, p. 23.
Kline,  W. A., DeVor,  R. E., and Lindberg,  J. R., 1982, “The Prediction of Cutting Forces in End Milling With Application to Cornering Cuts,” Int. J. Mach. Tool Des. Res., 22, pp. 7–22.
Fu,  H. J., DeVor,  R. E., and Kapoor,  S. G., 1984, “A Mechanistic Model for the Prediction of the Force System in Face Milling Operations,” ASME J. Ind., 106, pp. 81–88.
Chandrasekharan,  V., Kapoor,  S. G., and DeVor,  R. E., 1998, “A Mechanistic Model to Predict the Cutting Force System for Arbitrary Drill Point Geometry,” ASME J. Manuf. Sci. Eng., 120, pp. 563–570.
Kapoor,  S. G., DeVor,  R. E., Zhu,  R., Gajjela,  R., Parakkal,  G., and Smithey,  D., 1998, “Development of Mechanistic Models for the Prediction of Machining Performance: Model Building Methodology,” Mach. Sci. Technol., 2, pp. 213–238.
Surendaran, V., 1998, “A Study of Hole Quality in Drilling,” Master’s thesis, University of Illinois at Urbana-Champaign.
Chandrasekharan, V., 1996, “A Model to Predict the Three-Dimensional Cutting Force System for Drilling With Arbitrary Point Geometry,” PhD thesis, University of Illinois at Urbana-Champaign.

Figures

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Oblique cutting in tapping (a) straight-fluted tap (b) spiral-fluted tap (c) gun tap
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Oblique cutting mechanics of tapping
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Effective pitch relation with the thread pitch
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Process faults in tapping (a) tap and spindle runout (b) tap and hole axis misalignment
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Equivalent radius for tap offset from the hole, (a) tap position at 30 deg, (b) tap position at 60 deg, (c) tap position at 120 deg, (d) observed hole radius from the cutting edges of the four flutes of the tap as a function of tap rotation
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Cutting edges corresponding to flutes one through four for a simple/straight four-fluted tap. Axes U and X are along the tap axis and radial directions respectively
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Equivalent radius for tap offset from the spindle, (a) tap position at 0 deg, (b) tap position at 30 deg, (c) tap position at 90 deg, (d) observed hole radius from the cutting edges corresponding to the four flutes of the tap as a function of tap rotation
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Periodic trend observed in tapping torque and its power spectrum shows peak at 3.33 Hz=200 rpm
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Comparison of experimental and simulated results for axis misalignment
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Tapping torque simulations (a) without and (b) with runout for a tap size of M12×1.75 at 500 rpm with CI as workpiece material
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Illustrations of torque simulations for different sets of hole profile data. (a) hole profile along the depth, (b) hole taper effect on the torque, (c) hole profile along the depth and (d) hole barrelling effect on the torque.
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Polar plot of the measured hole radius along the circumference in the initial part of the hole
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Polar plot of the measured hole radius along the circumference in the final part of the hole

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