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A Review on Thread Tapping Operation and Parametric Study

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 Hardik J. Patel, Bhaveshkumar P. Patel, Prof. S. M. Patel / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 [Link]
Vol. 2, Issue 3, May-Jun 2012, pp.109-113

A Review on Thread Tapping Operation and

Parametric Study
Hardik J. Patel*, Bhaveshkumar P. Patel**, Prof. S. M. Patel***
*(M. Tech. student-AMT, Mechanical Engineering Department, U. V. Patel College of Engineering, Ganpat
University, Kherva- 384012, Dist. Mehsana, Gujarat, India)
** (Assistant Professor, Mechanical Engineering Department, U. V. Patel College of Engineering, Ganpat
University, Kherva- 384012, Dist. Mehsana, Gujarat, India)
** (Professor, H.O.D., Mechanical Engineering Department, U. V. Patel College of Engineering, Ganpat
University, Kherva- 384012, Dist. Mehsana, Gujarat, India)

ABSTRACT
Now days, there is a tremendous development in the inconsistent quality of tapping. Machine tapping can be
production industry and their relevant machinery to performed by electric drives and the problems concerned
improve the productivity. But still, in small, medium with the machine tapping can be eliminated with the
and some large scale industries uses the conventional application of pneumatic tapping machine.
methods in some of the operations. Thread tapping is
one of them. Tapping is the method to produce the fine II. FORMULATION OF PROBLEM
thread inside the drilled hole on the plate. Most of the A tap cuts a thread on the inside surface of a hole, creating
industries uses the conventional method says hand a female surface which functions like a nut. During
tapping. This conventional method is very time operation, it is necessary with a hand tap to periodically
consuming process, less accurate and includes higher reverse rotation to break the chip formed during the cutting
labour cost, and ultimately less productivity. So there is process, thus preventing an effect called "crowding" that
a scope to develop the machine for tapping operation. may cause breakage. Periodic reversing is usually not
This paper focuses on the review of the tapping practical when power tapping is involved, and thus has led
operation and its parametric study carried out by other to the development of taps suitable for continuous rotation
researchers in the same field. in the cutting direction.
Taps and machine tapping operation for internal
threads are amongst the most complex and least understood
Keywords - Machine tapping, Pneumatic, tap size cutting tools and cutting processes used in practice.
Tapping of a screw thread is one of the very common
I. INTRODUCTION machine operations used in manufacturing industry and is
There is a tremendous technological development in the frequently among the last operations performed on a
manufacturing industry and manufacturing industries are component so that the added value of the component is
making large amount of effort for their mass production close to its peak when tapping is performed. But tap
with best quality products having higher reliability and breakage may either ruin the almost finished work piece, or
economical in cost. Now days the hand operated machines create a large down time to remove the broken tap from the
are replaced with the application of automation in work piece. Other problems associated with the tapping
automatic or semi automatic machines which utilized to process include thread dimensional accuracy, thread form
improve the productivity. Tapping may either be achieved error, and surface roughness of thread form. For several
by hand tapping by using a set of taps first tap, second tap decades, it remains troublesome and costly due to various
& final (finish) tap or using a machine to do the tapping, process failures such as tap breakage, over- and under-
such as a lathe, radial drilling machine, bench type drill sized threads, and burrs at the entry and exit of threaded
machine, pillar type drill machine, vertical milling holes. These failures are usually caused by certain process
machines, HMCs, VMCs. Machine tapping is a process to faults that often exeunt in production. Small, medium and
produce the female threads inside the drilled hole. Machine some large scale industries still uses the conventional
tapping is faster and generally more accurate because methods to perform the tapping operation and faces the
human error is eliminated. Final tapping is achieved with above mentioned problems. As the industry strives for
single tap. Although in general machine tapping is more higher productivity and better quality, this is a need for the
accurate, tapping operations have traditionally been tapping process to operate without error or human
verytricky to execute due to frequent tap breakage and intervention. So here there is a chance to develop an air

109 | P a g e
 Hardik J. Patel, Bhaveshkumar P. Patel, Prof. S. M. Patel / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 [Link]
Vol. 2, Issue 3, May-Jun 2012, pp.109-113
tapping machine which can reduce or eliminate the above experimental program to study the influence of torsional
mentioned problems associated with tapping process and vibrations on tapping process. An attachment has been
study can be conducted for affecting parameters designed and developed to produce controlled torsional
responsible for better quality and improvement in vibration on the tap while tapping. Investigations have
productivity and economy. been carried out to study the influence of different process
conditions, such as tap size, work material, vibration
III. LITERATURE REVIEW amplitude and frequency, etc. on the tapping torque and
For the development of the new technique, operation, thrust during machining. Optimal process conditions which
process or methodology it is very important to make detail enhance the tap life are reported. The optimal frequency of
study on the existing techniques, operation, process or vibration corresponding to the maximum reduction in
methodology and to understand the same for elimination of tapping torque and thrust is different under different
problems concerned with them. This section covers the operating conditions. The optimal process conditions
literature review for tapping operation and its parametric observed for vibratory tapping process on cast iron and
study carried out by other researchers in the same field. aluminum. The optimal cutting conditions give about 8%
This study can be helpful for improving the quality of reduction in tapping torque and about 16 % reduction in
tapping, dimensional accuracy, and productivity, also thrust while tapping cast iron. For tapping in aluminum
reduced in operational timing, tool breakages, and human reduction in tapping torque and thrust was about 14% and
errors. 56% respectively. A critical uncut chip thickness value is
In 1973, E. D. Doyle and S. K. Dean have seen to exit below which only the reduction in tapping
designed tapping attachment to reduce the axial forces torques and thrust is possible. The critical uncut chip
generated during the tapping operation. When tapping thickness is found to increase with the decrease in the
threads on a machine tool, such as a drilling machine, axial hardness of the work material. The optimal value of the
forces on the tap can be generated by the cutting action of frequency increases with the decrease in uncut chip
the tap, by the operator and by the machine, and they can thickness. The optimal value of amplitude, for a given size
cause dimensional inaccuracies in the thread. Oversize of tap or uncut chip thickness, depends upon the hardness
threads and poor thread forms produced on a radial drill of the work material. Thus, it is seen that the vibratory
were found to be caused by axial forces generated by the tapping process is suitable under particular operating
machine. These defects were eliminated by using a tapping conditions [3].
attachment specifically designed to reduce axial forces. A
device for reducing the axial force was developed and its De-Yuan Zhang and Ding Chang Chen, in 1998,
have a one of the key problem in the tapping process to cut
use enables the cutting of accurate thread forms [1]. G.
materials such as titanium alloys is difficult in which the
Lorenz, in 1980, has studied on tapping torque and tap
relief-face friction of the tap is very large. The vibration
geometry. Vibrations in tap geometry are reflected in the
tapping process in which the spring back of the machined
measurements of the tapping torque. The effects of cutting
surface can be removed, has been analyzed with elasto-
speed, thread relief, chamfer and rake angle on torque have
plastically. Thus the reason why vibration tapping can
been investigated in a statistically designed experiment
when using 7/16 – 20 UNF bottoming taps and zp-oil on a
reduce the tapping torque has been explained qualitatively,
and a theoretically basics for choosing reasonable values
pitch gear controlled tapping machine. The analysis of the
for the cutting parameter for vibration tapping has been
experimental data showed that the higher order interactions
provided. The theoretically analysis shows good agreement
of the variables, in particular those of speed and chamfer
with the experimental results obtained when tapping a
relief, significantly affect the torque. The thread relief and
titanium alloy [4]. E. J. A Armarego and Marilyn N. P.
the chamfer relief must be selected for the tapping speed
Chen, in 2001, have developed cutting models for the
used in production, if the torque is to be reduced. At fast
forces and torque in machine tapping operations with
speeds only a combined increase of thread relief and rake
straight flute taps is outlined. The models, based on the
angle is expected to yield a substantial reduction in torque,
“unified- Generalized Mechanics of Cutting Approach”
which in turn will reduce the enlargement cut by the tap.
allow for the many tap and cut geometrical variables. The
The experiments also showed little change in tapping
torque around a rake angle of γ = 7º, when tapping CS
models have been verified by extensive computer
simulation studies as well as comprehensive experimental
1114 free machining steel. Furthermore, the results suggest
testing programmers. This investigation has provided a
that tapping torque measurements should be carried out at
deeper understanding of the basic cutting action as well as
three speed levels when the ratings of cutting fluids have to
be established [2]. predictive force models of tapping, renowned as “one of
the most neglected operation in machining research.
In 1987, S. S. Patil, S . S. Pande and S. Although this work has shown that both thrust and torque
Somasundaram have reported the results of an can now be predicted, further research is required to
110 | P a g e
 Hardik J. Patel, Bhaveshkumar P. Patel, Prof. S. M. Patel / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 [Link]
Vol. 2, Issue 3, May-Jun 2012, pp.109-113
improve the unbalanced side force prediction and to allow change with lubricating conditions. The coefficient for dry
for variables such as the tap helix angle and possible sliding is about 4 times that with cutting fluid lubrication.
eccentricity in the axis of rotation [5]. The coefficient of friction change with sliding speed,
usually decreasing as speed increases. There are only slight
Synchronizing error between the spindle motor differences between the friction coefficients measured with
and the z- axis motor directly influence the cutting different cutting fluids. Application of cutting fluids
characteristics in tapping, because the tapping processes is reduces the base tapping load, but has little effect on the
accomplished by synchronizing the movement of the z-axis peak load, and therefore is not a critical determinate in
with the revolutionary spindle motion. The excessive terms of tap breakage [7].
synchronizing error can cause tap breakage due to the
abrupt increases of cutting torque or damage the thread In 2002, Oleg A. Mezentsev, Rixin Zhu, Richard
accuracy by overcutting the already cut threads. This paper E. DeVor, Shiv G. Kapoor, and William A. Kline have
describes the affects of the synchronizing error on the developed a model based method for fault detection in
cutting performance in the ultra high speed tapping and tapping based on torque and radial forces. The method
presents a minimum level of synchronizing errors allows the identification of faults typical of a tapping
necessary to maintain the quality of the cut thread operation including axial misalignment, tap run-out, and
presented by J. h. Ahn, D. J. Lee, S. H. Kim, H. Y. Kim tooth breakage both singly and together. The validation
and K. K. Cha, in 2002. They have concluded that the experiments have been run on aluminum 356 work pieces
tapping torque pattern experimentally obtained with a near for different combinations of process faults. Results have
zero synchronizing error is well matched with the shown that the model predictions are in good agreement
simulated one based on the proposed theoretical model. with the experimental radial force and torque signals under
Synchronizing errors greatly vary according to the change various fault conditions. A mechanistic model for the tap
of feed forward gain as well as cutting speed. In the case of tapping process has been enhanced to study the effects of
large synchronizing errors, the tapping torque and thrust different tapping process faults on the force signals: torque
increase and the cut threads are damaged while retreating. and radial forces. Enhancement includes the occurrence of
Synchronizing errors should be controlled less than 0.04 runout axis misalignment and tooth breakage. The fault
mm, 8% of the pitch of the M3 tap, to meet the level of JIS identification strategy focuses on torque and redials forces
class 2 in the ultra- high speed tapping [6]. and is based on comparing experimental signals obtained
during cutting with those based on the model in the
Tengyun Cao and John W. Sutherland in 2002, a presence of various faults, namely tap axis misalignment,
mechanistic model for the prediction of tapping torque and tap runout, tooth breakage and their various combinations.
axial force is developed. The model is capable of Results of validation experiments show excellent
predicting tapping torque and axial force resulting from agreement between model simulations and experiments.
chip formation and tool flank work piece friction under The average prediction error of the magnitude of torque
various machining conditions including dry tapping and and radial forces is less than 10%. The error in predicting
tapping with different cutting fluids. Extensive tests on the mean of radial forces for the studies cases is less than
tapping torque and axial force measurements are conducted 15% [8].
to verify the predictive model. Characteristics of the
measured tapping loads are studied. It is found the total W. Li, D. Li and J. Ni have presented a two stage
tapping load consists of a base load and a chip packing pair wise feature selection and classification method to
load. The base load results from chip formation and diagnose the tapping process using the electrical current
tool/work piece friction. The predicted tapping load is signal of the spindle motor in the year 2003. The motor
found to be in good agreement with measured base load. current is measured with a non intrusive Hall Effect sensor.
The chip packing load is the result of chip clogging in the The diagnostics process is divided into two stages. The
flute, and is random in nature. The chip packing load may final diagnostic decision is made based on a statistical
be as large as five times that of the base load depending on voting procedure. The proposed method has been
tap geometries and the machining conditions. Factor demonstrated with experimental data. On average a 93%
causing severs chip clogging and excessive torques leading success rate has been achieved [9]. In 2003, Bi Zhang,
to tap breakage is also reported. Tap breakage was Fulun Yang and Jiexin Wang, have carried out a study on
observed to be torsional fracture resulting from excessive fundamental aspects in vibration-assisted tapping. A
tapping torque; particularly the random load from chip although tapping has been widely used for thread
clogging chip clogging may be reduced through optimized fabrication, it is often a time consuming process causing a
design in tap geometry with improved chip delay on an automated production line. This study
accommodation and chip evacuation. The coefficient of investigates the fundamental aspects in vibration-assisted
friction between tool material and work piece material was taping. It addresses two major mechanisms that are

111 | P a g e
 Hardik J. Patel, Bhaveshkumar P. Patel, Prof. S. M. Patel / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 [Link]
Vol. 2, Issue 3, May-Jun 2012, pp.109-113
responsible for torque reduction during vibration-assisted tapping process could be divided into six characteristics
tapping, i.e. friction torque reduction and material property stages. The implication associated with each characteristics
change at an enhanced strain rate. Theoretical analyses are stage was discussed for each plot. The stages where there
conducted to account for the effect of vibration on tapping was maximum thrust force and maximum torque located
torque reduction, and the verified by the tapping were indentified. For smaller size tapping of pure titanium
experiments with and without vibration assistance. Taps of metal, imposing an ultrasonic vibration can beneficially
three different sizes and vibration of two different affect the tapping process in terms of reducing the tapping
waveforms are used in the tapping experiments. The torque, and thereby decreasing the likelihood of the tap
theoretical results are applicable to vibration-assisted breakage. Within the adjustable range of the ultrasonic
tapping and other machining processes. For a given vibration generator, it was verified that vibration assisted
frequency of vibration, there exists an optimum amplitude tapping performed at the resonance frequency would have
at which the minimum tapping torque is obtained. More the lowest tapping torque generated. Introducing of cutting
reduction in tapping torque is obtained when a smaller size fluid during tapping had a beneficial effect in terms of
tap is used, and vice versa. A torque reduction is always reducing the tapping torque, though the degree of reduction
obtainable with vibration assistance in tapping. Vibration was less than that realizing by vibration. The smaller the
waveforms have influence on the tapping torque reduction. tap size was, the greater the degree of the tapping torque
Square waves have a better effect than sine waves [10]. reduction could be. No adverse effect on the profile of the
internal threads was noted when vibration-assisted tapping
J. D. Adams, L. Manning, B. Rogers, M. Jones was employed [13]. S. Bhowmick, M. J. Lukitsch, A. T.
and S. C. Minne, in 2005 have demonstrate self sensing Alaps, in 2010, have made study on the deep hole drilling
tapping mode using commercially available, low- stress, and tapping of automotive power train components made
piezoelectric cantilevers with sharp design integrated, on of hypoeutectic Ai-Si alloys and having considerable
silicon tips. Previous work has been limited by stress in the importance. This work investigates the dry and minimum
cantilever, thickness and size of the cantilevers, un- quantity lubricated (MQL) tapping of AI-6.5% Si (319)
optimized electrical trace design and/or a lack of a probing alloy as alternative to conventional flooded tapping. Two
tip. Tests indicate amplitude resolution with self-sensing to types of tests were done in comparison with flooded
be as good or better than optical detection, and sensitivities tapping. In the first set dry tapping experiments were
up to twice as good, with the same type cantilever. A performed using diamond like carbon (DLC) coated and
tapping mode image of an evaporated gold film and force uncoated HSS taps. The second set of tapping experiments
curves that compare optical and self-sensing detection used MQL and only uncoated HSS taps. The mechanicals
methods are presented [11]. A tapping operation having a properties of the material adjacent to tapped holes,
problem, as high-speed steel tap is incapable of tapping evaluated using hardness measurements, revealed a notable
small hole (M3) in hardened steel (50HRC). Theoretical softening in the case of HSS-dry tapping, but not for MQL
analysis with fracture mechanics indicates that the impact tapping. The presence of sulphur and phosphorus based
effect of the tap on the work piece results in increased H- additives in MQL fluids proved beneficial in preventing
type stress intensity factor and extended micro cracks, aluminum adhesion [14].
leading to lower plastic deformation, reduced cutting
forces and a much lower tapping torque and the torsional In 2010, G. Fromentin, A. Bierla, C. Minfray
rigidity of the tap is enhanced in vibration tapping as and G. Poulachon have presented the results of a study of
proved using dynamic analysis by Baolin Yin and Rongdi lubrication in form tapping and aims a better understanding
Han in 2006. The experimental results show that well of its effect. It appears that lubrication is of paramount
chosen amplitude tapping torque decreases as vibration importance. Oil with efficient high pressure additives can
frequency increases, and tapping torque increases as net reduce considerably the torque necessary to form the
cutting time ratio increases, where net cutting time ratio thread. Lubricants reduce the tool/work material friction
influences the tapping more significantly. Vibration during the forming process and as a consequence. This
tapping is then proved to be a practical solution to the investigation includes an analysis on the effect of additives
problem of small hole tapping in hardened steel [12]. in lubricants on the temperature during tapping, enabling
correlation with the appearance of chemical elements of
Kei-Lin Kuo, in 2007, has studed a vibration the oil which react with the thread material and contribute
assistance tapping for fabricating internal thread for to lubrication. The present study evaluated the ability of 9
titanium metal. High frequency imposed on the work piece, oil and 2 water based emulsions to reduce friction in form
was generated by a piezoelectric actuator. The axial thrust of tapping. From this study, important differences are
force and the tapping torque were respectively plotted shown to exit between these lubricants, and consequently
against the tap’s traveled distance relative to the work the choice of suitable oils for form tapping is necessary to
piece. Each of the plots demonstrated that the entire obtain success with this process. Thus, the key to
112 | P a g e
 Hardik J. Patel, Bhaveshkumar P. Patel, Prof. S. M. Patel / International Journal of Engineering
Research and Applications (IJERA) ISSN: 2248-9622 [Link]
Vol. 2, Issue 3, May-Jun 2012, pp.109-113
performance of a given lubricant in form tapping is surely and experimentation, International Journal of
determined by the molecular structure of the sulphur Machine tools & Manufacturing, ELSEVIER,
additive and its thermal behavior [15]. 42, 2002, 1527- 1538.
[8] Oleg A. Mezentsev, Rixin Zhu, Richard E.
IV. CONCLUSION DeVor, Shiv G. Kapoor, and William A. Kline,
The tapping operation is normally performed as end Use of radial forces for fault detection in
operation and very important for fastening purpose. tapping, International Journal of Machine tools
There are so many work carried out by the researchers & Manufacturing, ELSEVIER, 42, 2002, 479-
on tapping operation which includes the quality of 488.
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tapping tool with center of drilled hole, vibration assisted process using spindle motor current,
tapping, machine tapping, tapping tool breakages, International Journal of machine Tools &
application of different lubricants and its effect on Manufacturing, ELSEVIER, 43, 2003, 73-79.
quality, and parametric study and its analysis. Still there [10] Bi Zhang, Fulun Yang and Jiexin Wang,
is a scope to work on tapping operation with pneumatic Fundamental aspects in vibration assisted
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and improvement in productivity as well as to reduce the [11] J. D. Adams, L. Manning, B. Rogers, M. Jones
problems concerned with hand tapping and machine tool and S. C. Minne, Self sensing mode atomic
tapping which can eliminate major problem of tapping forces microscopy, Sensors and Actuators A,
tool breakage. ELSEVIER, 121, 2005, 262-266.
[12] Baolin Yin and Rongdi Han, Investigation of the
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characteristics through mechanistic modeling
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