How to reduce labor costs and improve tapped holes quality control inspection at the same time

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How to reduce labor costs and improve tapped holes quality control inspection at the same time

How do you control the quality of tapped holes? Do you also encounter a lot of tapping problems? For example, breakage, cutting-edge chipping or wear, etc., When these problems occurred, the tools did not reach the normal tool life, and a lot of defective products were produced. It is impossible to know whether there is a problem through the general torque and axial force, therefore, it also consumes a lot of manpower for quality control, so how should we improve it?

Introduction

CNC Tapping

Tapping refers to threading the inner wall of the hole and making threads so that the corresponding bolts or screws can be connected to it. CNC tapping has always been a complex process that is difficult to detect quality. It tests the synchronization and matching between motors, and the matching between parameters and tapping thread cutting tool is also very demanding, not to mention the overall accuracy and the quality after processing. Verification is very difficult. For decades, quality inspection has always been the soil method of using bolts to directly test the locking. As for whether the locking of the teeth holes is smooth, whether there is skew, whether the threads have large or small edges or the detection of chip squeezing in the holes under the tapped holes. Most of them require a lot of manpower for quality control to detect, and at this time, you can control the quality through real-time sensing of the "smart tool holder".

Analysis of the tap wear during the tapping process.

As shown in the above figure, it can be seen that the general traditional use of torque sensing, in which the movement of the tapping thread cutting tool can be known from the tip of the tap until it touches the guide hole, and the downward spiral tapping makes the twisted iron scraps neatly extruded from the chip removal groove, and then the overall strength signal circling against the trend, the signal quality seems to be all good.

Let's look at the axial force. When the tapping thread cutter is tapped, the axial direction is also loaded, but the overall feeling is that there are other cluttered signals. Maybe there is a quality issue, but we have no way of knowing.

Finally, let's look at the bending force. We can also see the force peaks generated by the torsion force and the axial force during tapping. But it can be clearly seen that this wave peak is superimposed by many small wave peaks, which is the key signal that the tapped hole is cut out of the thread instantly.
Have you noticed that there is a huge signal bulge on the far right? Torsional force and axial force cannot clearly observe this phenomenon. This is the signal that the twisted iron filings are cut out of the thread for the second time when the tapping cutter is rotated. This state is likely to cause poor quality of the tapped hole, and this subtle phenomenon can only be measured by bending force.

In Europe, many end users have already used the method of intelligent tapping, and no secondary quality inspection is required. The error rate of tooth holes is 0%, which has greatly reduced the cost of quality control.

The main picture provided by Ron Lach Link: Pexels

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