Finite element simulation of stresses in cutting tools during tapping

Abstract

Tapping is inherently more complex than other machining processes. The main reason for this complexity is that the chip removal process takes place in a closed environment. For this reason, in order to use the tap tools more efficiently, it is necessary to know the cutting conditions and the stresses that occur in the tool during cutting. In this study, holes of different diameters were drilled in the AISI 1050 material and threaded with M10 taps with three different geometries. Uncoated HSS and TiN coated HSS taps were used in the study. The tapping operations were carried out in dry conditions. The simulation conditions were chosen exactly the same as the experimental conditions. Stresses during tapping were analysed using the Third Wave AdvantEdge program based on the finite element method (FEM). The tapping tools were modelled by reverse engineering method and then imported in the program. In general, the coating applied to the tools positively affected the stresses on the cutting tool. Also, the stresses in tapping tools with helical were lower than in straight tools.

Finite element simulation of stresses in cutting tools during tapping

“…Then, STL format was transferred to Catia program and 3D models of point clouds of taps were obtained. 26 3D images of the tapping tools created with point clouds are given in Figure 1.…”

Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method

“…Due to the resizing of the elements during the chip formation process, degeneration of the elements is very common [20]. This degeneration in the network structure causes sudden/instantaneous increases or decreases in the force and torque values that occur during the simulation (Figure 4b) [23].…”

“…One of the important parameters that affects the thrust forces and torque values, is the chip type. Prediction of the chip type of the material to be machined is important in terms of the machining economy [23].…”