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In recent years, due to the development of modern processing technologies, the development of cutting tools has increased dramatically. This achievement greatly improved the production of mechanical products requiring threaded parts for precise and fast assembly.
Typically, these threads are created by cutting or forming taps during the final assembly of the component.
Internal threading is an extremely complex operation where the properties of the thread material, cutting fluid and threading tool must be adjusted to ensure quality and consistency.
The Bruker UMT TriboLabTM Torque Tester is designed to accurately analyze process performance and quickly monitor threading process parameters.
On fig. Figure 1 shows a threading torque test setup consisting of a UMT TriboLab, a high speed rotary drive, a torque sensor and a threading torque test kit. In a typical test, a pre-drilled 8.5 mm diameter workpiece was added to the sample holder and an unenclosed 10 gauge HSS tapping tool was inserted into the chuck holder of the machine.
Rice. 1. Torque on UMT TriboLab using bottom slewing drive kit. Image credit: Bruker Nano Surfaces
The holes in the workpiece were then filled with approximately 5 ml of metalworking fluid (MWF) as coolant and lubricant. In this study, the accuracy and accuracy of threading improved the synchronization characteristics between the rotational movements of the machine and the feed movements.
Three different shapes of pre-drilled hex blanks (6061-T6 aluminum, C360 brass, and 1215 steel) were used to demonstrate the capabilities of the drill (Figure 2). Conventional Heavy Duty MWF was used to lubricate the threading process without further dilution. Table 1 lists the investigated parameters.
For each test, threading was performed five times with different blanks. The system software provides data on torque, coefficient of friction, threading depth and real-time multi-channel data acquisition, which makes it easy to determine the effectiveness of threading torque.
In this work, the test method and evaluation strategy have been modified from two normative standards for threading torque testing: ASTM D5619 00 (2011) and ASTM D8288 19.2. In short, an M10 tap is screwed into the inside of the nut blank while the machine rotates in the other direction. The torque sensors in the system simultaneously collect the resulting torque readings.
On fig. 3 shows torque curves for three metals with large shear moduli (80 to 26 GPa) and hardness variations (Brinell hardness 95 to 167). This represents the most popular manufacturing applications such as brass for knurling and thread rolling, T6 aluminum for aircraft or marine fittings, and 1215 steel for bar or wire rolling.
Each element is tested five times to collect statistics and ensure the accuracy of the collected information.
Figure 3. Torque curves for three metals: (a) aluminum: (5.41+/-0.03) Nm, (b) brass: (7.40+/-0.05) Nm, (c) steel : (9.48+/-0.06) Nm Image credit: Bruker Nano Surfaces
Torque values for the three threaded nuts range from 5.4 Nm to 9.48 Nm. Based on these results, 6061-T6 aluminum, which provides the lowest torque of the three alloys, has the best machinability.
Due to its 50% higher hardness and 3 times higher shear modulus than brass or aluminum, 1215 steel, which has the highest torque value, is less machinable. Ultimately, the torque test rig at UMT TriboLab proved to be very reproducible, with a dispersion well below 1%, fully compliant with ASTM D5619 certification.
In addition to analyzing the performance of cutting taps described in this study, a similar approach can be used to analyze forming taps. Due to its high accuracy and short generation time, this scheme is suitable for extensive sorting of threading tools, cutting fluids, and machining materials.
Thread conditions can be changed in real time to quickly achieve ideal machining conditions and parts. Thanks to the modularity of the UMT TriboLab, the lubrication function can be easily checked with a 4-ball setup and the coating on the threading tool can be determined with a scratch test.
The Bruker UMT TriboLab Threading Torque Stand provides a flexible and practical way to evaluate combinations of tool material, cutting fluid and workpiece material. The performance of tapping and forming taps can be evaluated using taps of various sizes from M2 to M10 and their pre-drilled counterparts.
UMT TriboLab provides unrivaled adaptability and performance for many types of ASTM, DIN, SAE and other custom tests, complementing the torque test stand with the addition of additional sensors, automated test routines and data display.
This information has been obtained, verified and adapted from materials provided by Bruker Nano Surfaces.
Brooker Nano Surface. (July 6, 2022). How to analyze the machinability of alloys using torque. AZOM. Retrieved September 1, 2022 from https://www.azom.com/article.aspx?ArticleID=21729.
Brooker Nano Surface. “How to analyze the machinability of an alloy using torque”. AZOM. September 01, 2022 . September 1, 2022 .
Brooker Nano Surface. “How to analyze the machinability of an alloy using torque”. AZOM. https://www.azom.com/article.aspx?ArticleID=21729. (As of September 1, 2022).
Brooker Nano Surface. 2022. How to analyze the machinability of alloys using torque. AZoM, accessed 1 September 2022, https://www.azom.com/article.aspx?ArticleID=21729.
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Post time: Sep-02-2022