What is it about?
The conventional tapping tool development consists of costly investigative experiments. The development time and cost can be significantly reduced, if these test were replaced by virtual analyses, before the tool prototypes are fabricated. Compared to turning, milling and drilling, in which many valid simulative methods have been established, the tapping process has been given rather little research attention. In this paper an approach is presented, which could be used during the design phases, to predict the relative torque, so that resources, energy and cost can be saved. Based on a simulated reference model, which is in good agreement with corresponding experimental results, the problem of a long computing time could be solved by using a proper segmentation method, which offers a process simulation along the whole chamfer length. With an according mathematical model, the discontinuous torque curve could be summarized to a total load cycle.
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Why is it important?
Depending on the complexity of the geometry, the simulation of three-dimensional models requires a long computing time. In particular, the 3D FEM simulation of tapping processes thus often remains closed to industrial application. In this paper, the development of a 3D FEM tap simulation model for computing time reduction and a mathematical model for the evaluation with the experimental values, which allows the function of the automatic validation in the FEM simulation system, was presented. In doing so, the mathematical model fulfils the tasks of the automatic recognition of deflections that result from the simulation of the segmented 3D model. The localization of rising and falling values with the subsequent cumulative calculation to a global maximum torque was accomplished as well. Prior to this development, the simulation of a reference model was necessary in order to create a stable base.
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This page is a summary of: Segmented and mathematical model for 3D FEM tapping simulation to predict the relative torque before tool production, International Journal of Mechanical Sciences, August 2017, Elsevier, DOI: 10.1016/j.ijmecsci.2017.04.011.
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