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TECHNICAL PAPERS

Finite Element Modeling for Tap Design Improvement in Form Tapping

[+] Author and Article Information
Curtis Warrington, Shiv Kapoor, Richard DeVor

Department of Mechanical and Industrial Engineering,  University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906

J. Manuf. Sci. Eng 128(1), 65-73 (Apr 27, 2005) (9 pages) doi:10.1115/1.2117427 History: Received September 21, 2004; Revised April 27, 2005

The form tapping process typically yields unfinished threads known as split crests. Thread quality can be greatly improved by reducing the size and severity of split crest formation. This paper develops a finite element model to simulate form tapping with an eye towards the reduction of split crests. The model is validated against linear scratch experiments, and simulations are compared to actual tapping. The effects of various tap design parameters and tapping process conditions on the formation of split crests are investigated to strive toward an optimal tap design.

Copyright © 2006 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Thread profiles showing the formation of split crests in form tapping, from (8)

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Figure 2

Force profile in scratch direction showing effect of mesh refinement

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Figure 3

Mesh showing local mesh refinement in thread root and ridge regions

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Figure 4

Front ridge development as a function of interfacial friction factor m

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Figure 5

Custom tool made from tap blank (8)

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Figure 6

Ridge shape comparison between experimental and simulated ridges

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Figure 10

Full thread form for (a) experimental (8) and (b) simulation results showing void

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Figure 11

Tap perimeters used in actual tapping simulations

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Figure 12

Finite element model of a single tap tooth (Manufacturer B, 5th tool pass)

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Figure 13

Simulated split crest formation for two commercial form taps

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Figure 14

Split crest formation over the entry taper region for two commercial form taps

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Figure 15

Temperature profiles (in °C) and ridge cross-section for two heat generation factors (K)

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Figure 16

Front ridge fold-over due to high friction factor

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Figure 17

Ridge shape dependence on friction factor

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Figure 18

Ridge shape obtained with different entry taper angles

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Figure 19

Finished thread form for Cartridge brass and 2034-T351 aluminum

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Figure 7

Cross section of tool with axially consecutive teeth (8)

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Figure 8

Split crest formation, 8, 10, and 13 scratches (up to 65% thread)

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Figure 9

Split crest shape parameters defined

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