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Study on micro-forming taps with unequal fluteless spacing

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Abstract

Tools with unequal fluteless spacing (UFS) feature are used to cut different materials. The UFS tool and a traditional tool differ in terms of the angle between the two cutting edges. The UFS tool experiences smaller axial and radial cutting forces than the traditional tool so cutting vibration is reduced, tool life is increased, and the surface roughness of the workpiece increases. This study uses the smaller hole diameter (D), spindle speed (N), and cutting fluid concentration (C) for the central composite design (CCD). Minitab statistical software is used for the second-order response surface modeling of the maximum thread-filling rate (f) and the minimum torque (T) for micro-forming M1.2 mm taps using UFS on AL-7075 aluminum alloy. The analysis of variance (ANOVA) results for f and T show that D and C are the important parameters that affect f, and D, N, and C significantly affect T. Compared with the predicted conditions, the errors in f and T for the experiment are 2.51% and 2.25%, respectively. This study shows that the two second-order mathematical models that are derived using CCD and the response surface method (RSM) feature good prediction accuracy.

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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.

Funding

The authors received 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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Authors and Affiliations

  1. Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taiwan, 333326, Taoyuan, Republic of China

    Ming-Chang Wu & Chung-Chen Tsao

  2. Department of Intelligent Vehicles and Energy, Minth University of Science and Technology, 307304, Hsinchu, Taiwan, Republic of China

    ChienChung Chen

  3. Department of Mechanical Engineering, National Central University, 320327, Taoyuan, Taiwan, Republic of China

    Yen-Cheng Huang

  4. Department of Mechanical Engineering, Asia Eastern University of Science and Technology, 220303, New Taipei, Taiwan, Republic of China

    Hsing-Ming Teng

  5. He Zuan Machine Co., Ltd, 307001, Hsinchu, Taiwan, Republic of China

    Ling-Sheng Hsu

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  1. Ming-Chang Wu
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  3. Yen-Cheng Huang
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Contributions

Ming-Chang Wu: conceptualization, guided experimental process, supervision, and writing—review and editing the draft. Chien-Chung Chen: data curation, characterization, validation, analysis, and writing—original draft. Yen-Cheng Huang: conducted the tapping experiments and collection of data and software/plots. Hsing-Ming Teng: reading and summarization of all literature and writing—review and editing the draft. Ling-Sheng Hsu: conducted the manufacture of forming tap. Chung-Chen Tsao: conceptualization, project administration, funding acquisition, and revised some grammar. All the authors have read and agreed to the published version of the manuscript.

Corresponding authors

Correspondence to Ming-Chang Wu or Chung-Chen Tsao.

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Wu, MC., Chen, C., Huang, YC. et al. Study on micro-forming taps with unequal fluteless spacing. Int J Adv Manuf Technol 125, 4073–4081 (2023). https://doi.org/10.1007/s00170-023-11000-4

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  • DOI: https://doi.org/10.1007/s00170-023-11000-4

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