Optimization of Tool Geometric Parameters For a Small Fluteless Forming Tap (FFT)

Abstract

A small blind internal thread (SBIT) is used to firmly fasten some functional components to the cover of 3C electronic products. The small internal thread is made in a blind hole using a fluteless forming tap (FFT) that does not produce chips. However, the four geometric parameters (tool width (W), tooth root diameter (D2), front-end diameter (Df) and tooth angle (θ)) for the FFT affect the thread filling rate (f) and the minimum torque (T) for the tapping process. This study reports a Box-Behnken design (BBD) using DEFORM-3D (finite element model) and MINITAB (regression analysis) software to tap 7075-T6 aluminum alloy using a small FFT to achieve a repeatable thread filling rate and minimum torque. The experimental results show that the BBD accurately predicts and simulate the thread filling rate for tapping 7075-T6 aluminum alloy. The modelling software and the experimental design for this study can be used to optimize the design of tools that are used in industrial production.

Finite element simulation of stresses in cutting tools during tapping

“…They investigated the effects of cutting speed and feed rate on tool life. Wu et al 16 performed optimization of tool geometric parameters for a small fluteless forming tap (FFT). They used DEFORM-3D (finite element model) and MINITAB (regression analysis) in the study.…”