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I believe that many people have encountered the difficulty of testing the quality of the tapped hole. In fact, even if the machining process is stable and no chips are stuck, the quality of the tapped hole can only be temporarily considered as good, we cannot know when the quality of each tooth will be NG when the number of the tapped hole is larger or which hole will be considered as NG? Or, when it is over-processed will cause the teeth of the cutter to break in the hole. This article will continue the previous article to discuss how much benefit the tapping cutter can bring to the shop owner.
The tool's quality of life can be found in the research below. Under the same machine, parameters, and workpieces, the number of holes that can be tapped by each same type of thread milling cutter is different. Let's see what is going on?
The above two figures show that when the same type of new thread milling cutter just began machining, under the same processing quantity, the wear value of the blade is not the same, but the difference is very small, and after processing a certain number of workpieces, the difference of wear value between each cutter increased. When the experiment has processed nearly a thousand holes, some cutters were worn out and tapped out NG holes. At the end of the experiment, it was found that among the eight identical thread milling cutters, the best one could tap 1500 holes with good quality. The KPI difference of each milling cutter is as high as 1.5 times.
The traditional method is to rely on the experience of the number of tapped holes in the past and takes the minimum number of machining numbers as the tool change benchmark. Assuming that the machining cost of a hole is 2.5 $NTD, there will be a profit gap of 1250 $NTD. If smart tapping monitoring is not used will always replace the tool with the minimum number of holes to be machined because of the fear that the tool will break in the workpiece at some point, and eventually lose more profits.
Since the KPI of a thread milling cutter can be clearly defined, it is helpful to judge the cost-effectiveness of purchasing domestic tool and imported tool, and even select more suitable thread milling cutters, coating types, optimized parameters, motor characteristics, and hole depth. Even if this process has accumulated experience with traditional methods, it seems that the process has been optimized, but once the smart tool handle is used, in fact, more profits can be generated.
The main picture provided by Adobestock
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