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

Year 2024, EARLY VIEW, 1 - 1

Tuncer Demirel Selçuk Yağmur Yunus Kayır Abdullah Kurt

https://doi.org/10.2339/politeknik.1342932

Abstract

Threading with taps is a method frequently used in machining. Since this process takes place in a closed area due to its nature, some difficulties are encountered. In this study, the results of a previous experimental work were compared with the results of a simulation program. In the experimental work, the tapping process were performed by using M10 taps with three different geometries for the drilled holes on AISI 1050 material. Tapping operations were carried out with uncoated and TiN coated HSS tools.
For the simulatin program, the 3D CAD models of the tested taps were created by reverse engineering method and then imported into a simulation program, called Third Wave AdvantEdge program. The CAD models were evaluated by Third Wave AdvantEdge program based the finite element method. The thrust force, torque, chip formation occurring during the threading process were examined. It was concluded that the simulation and the experimental results were quite compatible.

Keywords

Tapping thrust force simulation chip forms finite element method.

Supporting Institution

Gazi üniversitesi Bilimsel Araştırma Projeleri Koordinasyon Birimi

Project Number

41/2007-04

Thanks

Yazarlar olarak, Gazi Üniversitesi – Bilimsel Araştırma Projeleri Koordinasyon Birimi (BAP) tarafından sağlanan mali desteği için teşekkür ederiz.

References

  • [1] Uzun G., “Ti6Al4V The investigation of the tapping problems of Ti6Al4V alloy”, PhD Thesis, Gazi University Graduate School of Natural and Applied Sciences, (2013).
  • [2] Kayır Y., “Effect of drilled hole diameter on thrust forces and torques for thread tapping on AISI 1050 stell with taps”, Uludağ University Journal of the Faculty of Engineering, 15(1): 1-13, (2010).
  • [3] Gökçe H., Yavuz M.. “The effect of cutting speed in tapping process with commercial purity molybdenum material HSS Tap”, Gazi Journal of Engineering Sciences, 5(3):237-243, (2019).
  • [4] Uzun G., Korkut İ., “The effects of cutting conditions on the cutting torque and tool life in the tapping process for AISI 304 stainless steel”, Materiali in Tehnologije, 50 (2): 275-280, (2016).
  • [5] Uzun G., Korkut İ., “The effect of cryogenic treatment on tapping” Int J Adv Manuf Technol, 67: 857-864, (2013).
  • [6] Ma YC., Wan M., Yang Y., Zhang WH., “Dynamics of tapping process”, International Journal of Machine Tools and Manufacture, 140: 34-47, (2019).
  • [7] Kayır Y., “The effect of hole diameter on thrust forces for tapping on an AA5083 alloy”, J. Fac. Eng. Arch. Gazi Univ., 25(4): 671-679, (2010).
  • [8] Yağır MO., Mete OH., “Numerical model analysis of an industrial product, drilling and tapping operations on reducing the mold design process”, Sakarya University Journal of Science, 21 (2): 131-140, (2017).
  • [9] Armarego EJA., Chen MNP., “Predictive cutting models for the forces and torque in machine tapping with straight flute taps”, CIRP Annals, 51 (1): 75-78, (2002).
  • [10] Cao T., Sutherland JW., “Investigation of thread tapping load characteristics through mechanistics modeling and experimentation”, International Journal of Machine Tools & Manufacture, 42:1527–1538, (2002).
  • [11] Henerichs M., Woβ F., Wegener K., “Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces”, CIRP Journal of Manufacturing Science and Technology, 9: 136-145, (2015).
  • [12] Lee SW., Kasten A., Nestler A., “A model for thread milling thrust forces ”, International Journal of Machine Tools and Manufacture, 46: 2057-2065, (2006).
  • [13] Araujo AC., Silveira JL., Jun MBG., DeVor R., “Influence of weave structure on delamination when milling CFRP”, Journal of Materials Processing Technology, 216: 199-205, (2015).
  • [14] Aydın M., “High-Speed Machining Process of Titanium Alloy: A Comprehensive Finite Element Modeling”, Journal of Polytechnic., 25(2): 813-826, (2022).
  • [15] Gökçe H., Çiftçi İ., “Investigation of Tool Wear When Milling Molybdenum and Its Alloys”, Journal of Polytechnic, DOI:10.2339/politeknik.1215548
  • [16] Akdulum A., Kayır Y., “Investigation of the Effect of U Drills with Different Properties on Thrust Force, Torque and Spindle Load”, Journal of Polytechnic, 26(1): 387-400, (2023).
  • [17] Şentürk BG., Fetvacı MC., Modelling and undercutting analysis of beveloid gears, International Journal of Non-Linear Mechanics”, J. Fac. Eng. Arch. Gazi Univ., 35(2): 901-915, (2020).
  • [18] Taslak E., Kalenderli Ö., “Electric field analysis of different electrode systems used for breakdown tests of insulating liquids with FEM”, J. Fac. Eng. Arch. Gazi Univ., 33(3): 821-831, (2018).
  • [19] Eren Ş., Poyraz B., Gökçe N., Şamandar A., Aykanat B., Subaşı S., “Investigation of the initiator effect on mechanical, thermal and chemical properties of polyesters used in composite material production”, J. Fac. Eng. Arch. Gazi Univ., 33(4): 1383-1396, (2018).
  • [20] Biermann D., Oezkaya E., “CFD simulation for internal coolant channel design of tapping tools to reduce tool wear”, CIRP Annals, 66(1): 109-112, (2017).
  • [21] Kheireddine AH., Ammouri AH., Lu T., Jawahir IS., Hamade RF., “An FEM analysis with experimental validation to study the hardness of in-process cryogenically cooled drilled holes in Mg AZ31b”, Procedia CIRP, 8: 588-593, (2013).
  • [22] Yıldız A., Kurt A., Yağmur S., “Finite element simulation of drilling operation and theoretical analysis of drill stresses with the deform-3D”, Simulation Modelling Practice and Theory, 104 (102153): 1-17, (2020).
  • [23] Demirel T., “Investigation of cutting tool stresses based on cutting parameters in thread tapping”, M. Sc. Thesis, Gazi University Graduate School of Natural and Applied Sciences, (2019).
  • [24] Korkmaz ME., Çakıroğlu R., Yaşar N., Özmen R., Günay M., “Finite element analysis of thrust force in drilling of al2014 aluminum alloy”, El-Cezeri Journal of Science and Engineering, 6(1): 193-199, (2019).
  • [25] Gökçe H., Çiftçi İ., Gökçe H., “An investigation into the experimental and finite element analysis of thrust forces in milling: a study on machining of püre molybdenum”, Journal of Polytechnic, 22(4): 947-95 (2019).
  • [26] Budak E., Ozlu E., “Development of a thermomechanical cutting process model for machining process simulations”, CIRP Annals, 57(1): 97-100, (2008).
  • [27] Soldani X., Moufki A., Molinari A., Budak E., Özlü E., “High speed machining of AISI 1050 steel: modelling and experimental”, International Journal of Material Forming, 1(1): 1439-1441, (2008).
  • [28] Yağmur S., Acır A., Şeker U., Günay M., “An experimental investigation of effect of cutting parameters on cutting zone temperature in drilling”, J. Fac. Eng. Arch. Gazi Univ., 8: 1-6, (2013).
  • [29] Aydın M., “Finite element modeling of the residual stresses in orthogonal machining process”, Journal of Polytechnic, 19(3): 297-304, (2016).
  • [30] Aslantaş K., “Stress analysis in cutting tools coated tin and effect of the friction coefficient in tool-chip interface”, Pamukkale University Journal of Engineering Sciences, 9(2): 185-190, (2011).

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

Year 2024, EARLY VIEW, 1 - 1

Tuncer Demirel Selçuk Yağmur Yunus Kayır Abdullah Kurt

https://doi.org/10.2339/politeknik.1342932

Abstract

Threading with taps is a method frequently used in machining. Since this process takes place in a closed area due to its nature, some difficulties are encountered. In this study, the results of a previous experimental work were compared with the results of a simulation program. In the experimental work, the tapping process were performed by using M10 taps with three different geometries for the drilled holes on AISI 1050 material. Tapping operations were carried out with uncoated and TiN coated HSS tools.
For the simulatin program, the 3D CAD models of the tested taps were created by reverse engineering method and then imported into a simulation program, called Third Wave AdvantEdge program. The CAD models were evaluated by Third Wave AdvantEdge program based the finite element method. The thrust force, torque, chip formation occurring during the threading process were examined. It was concluded that the simulation and the experimental results were quite compatible.

Keywords

Tapping thrust force simulation chip forms finite element method.

Project Number

41/2007-04

References

  • [1] Uzun G., “Ti6Al4V The investigation of the tapping problems of Ti6Al4V alloy”, PhD Thesis, Gazi University Graduate School of Natural and Applied Sciences, (2013).
  • [2] Kayır Y., “Effect of drilled hole diameter on thrust forces and torques for thread tapping on AISI 1050 stell with taps”, Uludağ University Journal of the Faculty of Engineering, 15(1): 1-13, (2010).
  • [3] Gökçe H., Yavuz M.. “The effect of cutting speed in tapping process with commercial purity molybdenum material HSS Tap”, Gazi Journal of Engineering Sciences, 5(3):237-243, (2019).
  • [4] Uzun G., Korkut İ., “The effects of cutting conditions on the cutting torque and tool life in the tapping process for AISI 304 stainless steel”, Materiali in Tehnologije, 50 (2): 275-280, (2016).
  • [5] Uzun G., Korkut İ., “The effect of cryogenic treatment on tapping” Int J Adv Manuf Technol, 67: 857-864, (2013).
  • [6] Ma YC., Wan M., Yang Y., Zhang WH., “Dynamics of tapping process”, International Journal of Machine Tools and Manufacture, 140: 34-47, (2019).
  • [7] Kayır Y., “The effect of hole diameter on thrust forces for tapping on an AA5083 alloy”, J. Fac. Eng. Arch. Gazi Univ., 25(4): 671-679, (2010).
  • [8] Yağır MO., Mete OH., “Numerical model analysis of an industrial product, drilling and tapping operations on reducing the mold design process”, Sakarya University Journal of Science, 21 (2): 131-140, (2017).
  • [9] Armarego EJA., Chen MNP., “Predictive cutting models for the forces and torque in machine tapping with straight flute taps”, CIRP Annals, 51 (1): 75-78, (2002).
  • [10] Cao T., Sutherland JW., “Investigation of thread tapping load characteristics through mechanistics modeling and experimentation”, International Journal of Machine Tools & Manufacture, 42:1527–1538, (2002).
  • [11] Henerichs M., Woβ F., Wegener K., “Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces”, CIRP Journal of Manufacturing Science and Technology, 9: 136-145, (2015).
  • [12] Lee SW., Kasten A., Nestler A., “A model for thread milling thrust forces ”, International Journal of Machine Tools and Manufacture, 46: 2057-2065, (2006).
  • [13] Araujo AC., Silveira JL., Jun MBG., DeVor R., “Influence of weave structure on delamination when milling CFRP”, Journal of Materials Processing Technology, 216: 199-205, (2015).
  • [14] Aydın M., “High-Speed Machining Process of Titanium Alloy: A Comprehensive Finite Element Modeling”, Journal of Polytechnic., 25(2): 813-826, (2022).
  • [15] Gökçe H., Çiftçi İ., “Investigation of Tool Wear When Milling Molybdenum and Its Alloys”, Journal of Polytechnic, DOI:10.2339/politeknik.1215548
  • [16] Akdulum A., Kayır Y., “Investigation of the Effect of U Drills with Different Properties on Thrust Force, Torque and Spindle Load”, Journal of Polytechnic, 26(1): 387-400, (2023).
  • [17] Şentürk BG., Fetvacı MC., Modelling and undercutting analysis of beveloid gears, International Journal of Non-Linear Mechanics”, J. Fac. Eng. Arch. Gazi Univ., 35(2): 901-915, (2020).
  • [18] Taslak E., Kalenderli Ö., “Electric field analysis of different electrode systems used for breakdown tests of insulating liquids with FEM”, J. Fac. Eng. Arch. Gazi Univ., 33(3): 821-831, (2018).
  • [19] Eren Ş., Poyraz B., Gökçe N., Şamandar A., Aykanat B., Subaşı S., “Investigation of the initiator effect on mechanical, thermal and chemical properties of polyesters used in composite material production”, J. Fac. Eng. Arch. Gazi Univ., 33(4): 1383-1396, (2018).
  • [20] Biermann D., Oezkaya E., “CFD simulation for internal coolant channel design of tapping tools to reduce tool wear”, CIRP Annals, 66(1): 109-112, (2017).
  • [21] Kheireddine AH., Ammouri AH., Lu T., Jawahir IS., Hamade RF., “An FEM analysis with experimental validation to study the hardness of in-process cryogenically cooled drilled holes in Mg AZ31b”, Procedia CIRP, 8: 588-593, (2013).
  • [22] Yıldız A., Kurt A., Yağmur S., “Finite element simulation of drilling operation and theoretical analysis of drill stresses with the deform-3D”, Simulation Modelling Practice and Theory, 104 (102153): 1-17, (2020).
  • [23] Demirel T., “Investigation of cutting tool stresses based on cutting parameters in thread tapping”, M. Sc. Thesis, Gazi University Graduate School of Natural and Applied Sciences, (2019).
  • [24] Korkmaz ME., Çakıroğlu R., Yaşar N., Özmen R., Günay M., “Finite element analysis of thrust force in drilling of al2014 aluminum alloy”, El-Cezeri Journal of Science and Engineering, 6(1): 193-199, (2019).
  • [25] Gökçe H., Çiftçi İ., Gökçe H., “An investigation into the experimental and finite element analysis of thrust forces in milling: a study on machining of püre molybdenum”, Journal of Polytechnic, 22(4): 947-95 (2019).
  • [26] Budak E., Ozlu E., “Development of a thermomechanical cutting process model for machining process simulations”, CIRP Annals, 57(1): 97-100, (2008).
  • [27] Soldani X., Moufki A., Molinari A., Budak E., Özlü E., “High speed machining of AISI 1050 steel: modelling and experimental”, International Journal of Material Forming, 1(1): 1439-1441, (2008).
  • [28] Yağmur S., Acır A., Şeker U., Günay M., “An experimental investigation of effect of cutting parameters on cutting zone temperature in drilling”, J. Fac. Eng. Arch. Gazi Univ., 8: 1-6, (2013).
  • [29] Aydın M., “Finite element modeling of the residual stresses in orthogonal machining process”, Journal of Polytechnic, 19(3): 297-304, (2016).
  • [30] Aslantaş K., “Stress analysis in cutting tools coated tin and effect of the friction coefficient in tool-chip interface”, Pamukkale University Journal of Engineering Sciences, 9(2): 185-190, (2011).
There are 30 citations in total.

Details

Primary Language English
Subjects Manufacturing Processes and Technologies (Excl. Textiles)
Journal Section Research Article
Authors

Tuncer Demirel 0000-0002-0405-9240

Selçuk Yağmur 0000-0001-7036-297X

Yunus Kayır 0000-0001-6793-7103

Abdullah Kurt 0000-0002-7650-3443

Project Number 41/2007-04
Early Pub Date December 8, 2023
Publication Date
Submission Date August 14, 2023
Published in Issue Year 2024 EARLY VIEW

Cite

APA Demirel, T., Yağmur, S., Kayır, Y., Kurt, A. (2023). Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method. Politeknik Dergisi1-1. https://doi.org/10.2339/politeknik.1342932
AMA Demirel T, Yağmur S, Kayır Y, Kurt A. Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method. Politeknik Dergisi. Published online December 1, 2023:1-1. doi:10.2339/politeknik.1342932
Chicago Demirel, Tuncer, Selçuk Yağmur, Yunus Kayır, and Abdullah Kurt. “Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method”. Politeknik Dergisi, December (December 2023), 1-1. https://doi.org/10.2339/politeknik.1342932.
EndNote Demirel T, Yağmur S, Kayır Y, Kurt A (December 1, 2023) Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method. Politeknik Dergisi 1–1.
IEEE T. Demirel, S. Yağmur, Y. Kayır, and A. Kurt, “Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method”, Politeknik Dergisi, pp. 1–1, December 2023, doi: 10.2339/politeknik.1342932.
ISNAD Demirel, Tuncer et al. “Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method”. Politeknik Dergisi. December 2023. 1-1. https://doi.org/10.2339/politeknik.1342932.
JAMA Demirel T, Yağmur S, Kayır Y, Kurt A. Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method. Politeknik Dergisi. 2023;:1–1.
MLA Demirel, Tuncer et al. “Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method”. Politeknik Dergisi, 2023, pp. 1-1, doi:10.2339/politeknik.1342932.
Vancouver Demirel T, Yağmur S, Kayır Y, Kurt A. Investigation of Thrust Force, Torque and Chip Formation in Tapping Threading by Finite Element Method. Politeknik Dergisi. 2023:1-.

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