Analysis of tapping process in three types of cast iron

Pereira, Igor Cézar; Silva, Márcio Bacci da; Cunha, Daniel Fernandes da; Sales, Wisley Falco

doi:10.1007/s00170-015-7430-6

Cited by 17 publications

(7 citation statements)

References 5 publications

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“…Pereira et al. 18 also studied the use of MQL in tandem with the tapping of cast iron. The application of oil with a frequency of 1 pulse per second and a flow rate of 30 mL/h was enough to minimise torque, the axial force and tool wear.…”

Section: Discussionmentioning

confidence: 99%

“…In this study, M3 threads with pitch 0.5 mm were manufactured, and the results demonstrated that the forming tapping forces were minimal but proportionally superior to the machine tapping forces. In the research carried out by Pereira, 18 the threading of different materials was analysed, and the feed force was monitored. The resulting values demonstrate that form tapping always will produce feed forces that are greater than the feed forces from machine tapping.…”

Section: Discussionmentioning

confidence: 99%

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Performance evaluation of tapping processes using a 7075 aluminium alloy with different cooling systems and threading heads

Coelho

Pereira

Lauro

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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Modern industry faces a great challenge: the production of consumer goods based on a triangle comprising low costs, low production time and high quality. The optimisation of modern manufacturing processes should seek not only the reduction of manufacturing time but also the reduction of mineral resources and electric energy consumption. In the context of metalworking, considering tapping processes, studies on the use of minimum quantity of lubricant are minimal and scarce. Hence, this study deals with the application of minimum quantity of lubricant and emulsion to the processes of form and machine tapping. To this end, 7075-T651 aluminium alloy workpieces were threaded using both tapping processes at three cutting/forming speeds. M10 threads with a pitch of 1.5 mm were considered the standard profile. Torque and thrust force were monitored, and three threading heads were employed in the experimental tapping tests. According to the results, it can be concluded that the best option was to use minimum quantity of lubricant in order to reduce environmental impact, given its efficient disposal of fluids and compatibility with Softsynchro threading heads, which kept both torque and axial force close to the mean values. Furthermore, this threading head model was also the best for reducing the manufacturing time of the threads.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Performance evaluation of tapping processes using a 7075 aluminium alloy with different cooling systems and threading heads

Coelho

Pereira

Lauro

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…The tapping torque test was used to determine the role of the surfactant's molecular structure in MWFs as it is very sensitive to lubrication condition [44,45]. Formulations were evaluated based on the standard ASTM D5619 for comparing metal removal fluids [46].…”

Section: Tapping Torque Test For Tribological Studymentioning

confidence: 99%

The Role of Surfactant Structure on the Development of a Sustainable and Effective Cutting Fluid for Machining Titanium Alloys

Benedicto

Rubio

Carou

et al. 2020

Metals

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In cutting operations of titanium alloys, most of the problems are related to the high consumption of cutting tools due to excessive wear. An improvement of metalworking fluid (MWF) technology would increase the productivity, sustainability, and quality of machining processes by lubricating and cooling. In this research article, the authors varied the surfactant’s charge, the hydrocarbon chain length, and the ethoxylation degree. Surfactants were dispersed at 1.2 mM in water and trimethylolpropane oleate to produce water-based MWF. Infrared reflection absorption spectroscopy and total organic carbon analysis were used to study the influence of surfactant structure on the film forming ability of the emulsion and performance was studied on Ti6Al4V using tapping torque test. The results showed that by changing the molecular structure of the surfactant, it is possible to vary the affinity between the ester and the substrate and reach an optimal combination, which improves the formation of a tribofilm. The mixture with anionic surfactants has good tribology performance, while non-ionic surfactants shorten the tool’s life. Moreover, the increase in the hydrocarbon chain length and the number of ethoxylations of surfactants promotes the adhesion of ester onto the metal surface, improving the lubricity properties of environmentally friendly MWF.

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“…Essential for the force measurement of each individual tooth is that there is a temporally separated tooth engagement. Some papers therefore describe analogous processes in which parts of the tool are ground back [28][29][30]. This however results in a destruction of the tool, making further tests with the exact tool impossible.…”

Section: Single Tooth Analogy Processmentioning

confidence: 99%

Measuring and modelling of process forces during tapping using single tooth analogy process

Geßner¹,

Weigold²,

Abele³

2020

Prod. Eng. Res. Devel.

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For machining internal threads, tapping is a commonly used process. However, due to the complex geometry of the tapping tool, each tooth has a unique geometry resulting in individual forces. Since the forces act synchronously during the process, they partly compensate each other. However, since resulting forces in tapping can cause undesired deflection of the tool which can lead to threads that are not true to gauge or tool breakage, the knowledge of the forces is crucial. To predict the occurring forces on each tooth, different modelling approaches can be used. An approach based on the chip load-cutting force relationship is the mechanistic modelling. Therefore, a suitable force model is of central importance. An empirical force model can be established using an analogy process. Within this work a single tooth analogy process is presented to measure the forces of each tooth separately. By means of a geometrical analysis of the real tool, the chip sizes, such as the cross-section area of the undeformed chip are calculated. Merging the measured process forces from the analogy process and the actual chip sizes, an empirical force model is set up using multivariate regression. The model is validated by implementing it in an existing framework and comparing the results to experimental data.

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Analysis of tapping process in three types of cast iron

Cited by 17 publications

References 5 publications

Performance evaluation of tapping processes using a 7075 aluminium alloy with different cooling systems and threading heads

Performance evaluation of tapping processes using a 7075 aluminium alloy with different cooling systems and threading heads

The Role of Surfactant Structure on the Development of a Sustainable and Effective Cutting Fluid for Machining Titanium Alloys

Measuring and modelling of process forces during tapping using single tooth analogy process

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