Abstract
The small blind internal thread (SBIT) plays a very important role to firmly fastening some functional components on the cover of 3C electronic products. The small internal thread was made in a blind hole using a fluteless forming tap (FFT) without producing chips. However, the four geometric parameters of the FFT (tool width (W), tooth root diameter (D2), front-end diameter (Df), and tooth angle (θ)) will affect the thread filling rate (f) and minimum torque (T) in tapping process. This study reports the Box-Behnken design (BBD), combined with DEFORM-3D (finite element model) and MINITAB (regression analysis) software, to tap 7075-T6 aluminum alloy with small FFT to obtain reliable results of thread filling rate and minimum torque. The experimental results show that the BBD can accurately predict and simulate the thread filling rate of tapping 7075-T6 aluminum alloy. The modeling software and experimental design used in this research are very suitable for the optimal design of the FFT used in industrial production.
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Acknowledgements
The authors gratefully acknowledge the support of the Ministry of Science and Technology of the Republic of China, through Grant nos. MOST 108-2221-E-262-002-MY2.
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The authors appreciate the financial support of the Ministry of Science and Technology of the Republic of China (MOST 108–2221-E-262–002-MY2).
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M-CW: Conceptualization, guided experimental process, data curation, characterization, validation, analysis, supervision, and writing—review and editing draft. W-RJ: Conducted the simulation, methodology, tapping experiments, and writing-original draft. L-SH: Conducted the manufacture of forming tap. C-CT: Conceptualization, project administration, funding acquisition, and revised some grammar. All authors have read and agreed to the published version of the manuscript.
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Wu, MC., Jian, WR., Hsu, LS. et al. Optimization of tool geometric parameters for a small fluteless forming tap (FFT). Int J Adv Manuf Technol 120, 3437–3449 (2022). https://doi.org/10.1007/s00170-022-08955-1
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DOI: https://doi.org/10.1007/s00170-022-08955-1