Predictive Cutting Models for the Forces and Torque in Machine Tapping with Straight Flute Taps

In this paper the development of predictive cutting models for the forces and torque in machine tapping operations with straight flute taps is outlined. The models, based on the ‘Unified-Generalised Mechanics of Cutting Approach’, allow for the many tap and cut geometrical variables, the cutting speed and the toolcoating-workpiece material combinations. The models have been verified by extensive computer simulation studies as well as comprehensive experimental testing programmes. This investigation has provided a deeper understanding of the basic cutting action as well as predictive force models of tapping, renowned as “one of the most neglected operation in machining research”.